CONVERSION INSTRUCTIONS LP to NATURAL GAS (SEA LEVEL to 2000 FEET) Cast Iron Gas Fired Water Boilers 15B, UH15B, BWB, GMGWB for Forced Hot Water

Home , Gas burner

CONVERSION INSTRUCTIONS LP TO NATURAL GAS (SEA LEVEL TO 2000 FEET) Cast Iron Gas Fired Water Boilers 15B, UH15B, BWB, GMGWB For Forced Hot Water

WARNING KIT CONTENTS ! ITEM QTY. This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s Installation Instructions 1 instructions and all applicable codes and requirements Conversion Plate/Label 1 of the authority having jurisdiction. If the information Pilot Orifice - Spark 1 in these instructions is not followed exactly, a fire, Pilot Orifice - 24 Volt 1 an explosion or production of carbon monoxide may Liquid Sealing Compound 1 result causing property damage, personal injury or loss of life. The qualified service agency is responsible Spring Kit 1 for the proper installation of this kit. The installation PILOT ORIFICES is not proper and complete until the operation of the MFG. PART NUMBER converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit. Honeywell 390686-4* Tools Required *Use 390686-37 for Boilers Manufactured before July 2008 with Q381 Pilot. Flat Head Screwdriver, 1/4” Nut Driver, 7/16” Open Ended Wrench, 3/16” Allen Wrench, 18” Manometer (or dial Figure 1 manometer) Installation BURNERS

1. Turn off gas supply to the boiler. GAS VALVE KNOB ! WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

2. Turn off all electrical to boiler. ORIFICES 3. Remove front panel. 4. Remove burner access door. 5. Remove main gas burner tubes. See Figure 1. Figure 2 6. Remove main burner orifices. See Figure 1. 7. Install supplied natural gas main burner orifices. See Pilot table for orifice size and quantities. 8. Use 7/16” wrench, disconnect pilot tube from pilot. See Figure 2. 9. Remove pilot orifice. See Figure 2. 10. Install natural gas pilot orifice. See Figure 2. Pilot Orifice 11. Apply liquid sealing compound to threads of pilot assembly fitting. 12. Attach pilot tube to pilot and securely tighten. See Figure 2. Pilot Tube 13. Replace LP main burner tubes, if present, with natural gas tubes. See Figure 3.

P/N 24004820, Rev. E [11/2014] LP TO NATURAL GAS CONVERSION INSTRUCTIONS 14. Remove the cover screw from gas valve pressure regulator. See Figure 4. ! CAUTION WHAT TO DO IF YOU SMELL GAS 15. Remove adjustment screw by turning counterclockwise . See Figure 5. • Do not try to light any appliance. 16. Remove red LP gas spring. See Figure 5. • Do not touch any electrical switch; do not use NOTICE any phone in your building. • Immediately call your gas supplier from a Parts for steps 17, 18, 26, and 27 are located in the neighbor’s phone. Follow gas supplier’s Honeywell natural gas conversion kit HW#394588 instructions. (#VG00802) for VR8200, VR8204, VR8300 or VR8304 gas valve or conversion kit HW#391936 • If you cannot reach your gas supplier, call the fire (#VG00701) for VR8440 gas valve. department.

MAIN BURNER ORIFICES 17. Insert stainless steel natural gas spring. See Figure 5. INPUT ORIFICE 18. Install adjustment screw. Verify screw top is flush with QTY. regulator top. (Btuh) (mm) 19. Turn pressure regulator adjustment screw clockwise 45,000 3.1 1 eight (8) complete turns. This is starting point 70,000 2.8 2 for manifold pressure. 96,000 3.2 2 Install manometer to pressure tap on outlet side of gas 20. 120,000 2.9 3 valve. See Figure 4. 21. Turn ON electric and gas supply. 145,000 3.2 3 170,000 2.9 4 NOTICE 175,000 3.0 4 Verify gas inlet pressure is between minimum of 5” 195,000 3.2 4 w.c. maximum of 14” w.c. 245,000 3.2 5 295,000 3.2 6 22. Check for gas leaks around all gas connections using commercially available soap solution specifically made for leak detection. Figure 3 - Burners

! DANGER LP -X Fire Hazard. Do not use matches, candles, open ONLY flames, or other methods providing ignition source. Failure to comply will result in death or serious injury. NAT/LP 23. With boiler operating adjust manifold pressure to 3½” water column by turning pressure regulator adjustment screw. Figure 4 - Gas Valve 24. Turn OFF electric and gas supply. 25. Remove manometer. Replace pressure tap cover screw securely. 26. Install silver natural gas regulator adjustment cover screw with o-ring. See Figure 5. 27. Mount conversion label on gas valve. 28. Turn electric and gas supply ON. 29. Cycle boiler to ensure proper operation and lighting. 30. Replace front panel. 31. Fill out and affix conversion plate adjacent to rating plate. Complete this step to provide proper identification for customer service or technical support issues. 2 SEQUENCE OF OPERATION

• Thermostat actuates on call for heat, completing circuit Figure 5 - Gas Valve to control. • Completed circuit to control activates circulator. Damper will close end switch inside the damper. This will complete circuit to ignition system and ignition takes place. • Power is interrupted between control system and ignition system if boiler water temperature exceeds high limit setting on boiler mounted high limit control. Power remains off until boiler water temperature drops below high limit setting. Circulator continues to operate under this condition until thermostat is satisfied. • Blocked flow of combustion products through boiler venting system causes blocked vent safety switch to shut main burner gas off. If boiler flueway becomes blocked, flame rollout safety switch will shut main burner gas off. See Figure 6. If either condition occurs, do not attempt to place boiler back into operation. Contact qualified service agency. Figure 6 - Burners, Gas Valve, & Manifold • Main burner flame should have well defined inner blue mantel with lighter blue outer mantel. See Figure 7. • Pilot flame should envelop ⅜ to ½ inch of tip of the pilot thermocouple, ignition/sensing electrode or mercury sensor. See Figure 8.

Checking Gas Input Rate To Boiler • Adjust gas input to boiler by removing protective cap on pressure regulator and turning screw clockwise to increase input and counterclockwise to decrease input. • Set natural gas manifold pressure at approximately 3.5 inches water column. Manifold pressure is taken at outlet side of gas valve. • To check for proper flow of natural gas to boiler, divide input rate shown on rating plate by heating value of gas obtained from local gas company. This will determine number of cubic feet of gas required per hour. • With all other gas appliances off, determine flow of gas through meter for two minutes and multiply by 30 to Figure 7 - Burner with Mantel get hourly rate. Make minor adjustments to gas input as described above. • Change burner orifices if final manifold pressure varies more than plus or minus 0.3 inches water column from specified pressure. • Primary air adjustment is not necessary, therefore air shutters are not furnished as standard equipment. Air shutters are available on request where required by local codes or conditions.

3 LP TO NATURAL GAS CONVERSION INSTRUCTIONS

Figure 8 - Pilot

Ignition Electrode 3/8” To 1/2” In Flame